Protected metal roofing



l 192 luy 19 7 T. ROBINSON PROTECTED METAL HOOFINCT Filed May 6. 1926 BY nm `zfw ATTORNEYS Parenteel July 19, 1927.

UNITED .STATES THOMAS IR'OBIIIIEI'SON,- 0F NEW' YORK, N. Y.

PBOTEGTED METAL BOOFING.

Application led lay 6,

This invention relates to prepared building materials suitable especially for the roofs and walls of buildings, and the invention is more particularly concerned with theprovision of a building material which possesses all the advantages oflrigidity and strength of metallic materials, but 1S of A greater durability and improved appearance.

' operation,

a substa-ntia ly Metallic rooting and siding materialis now commonly used in buildings for industrial and other purposes, where an inexpensive construction is desired and the material` is usually in the form of iron sheets which may be either plain o'r corrugated. These sheets are of arelatively heavy gauge and in one common form are oblong in shape and from six to eight feet long and approximately three feet 1n width. These `sheets are laid on the roof in the .usual way, and ordinarily the metal employed is galvanized so that corrosion will vbe resisted. Such" treatment, however, is onl temporarily effective, and in a short time the metal rusts, thel corrosion proceeding rapidly where the atmosphere contains acid fumes. The life ofsuch material is consequently limited and the material, which, when newly laid, does not have a particularly attractive a comes especially unsightly a gins. l

The object of the present invention is to provide a building material of improved appearance and long life which may be made pearance, be-

. m any form desired, at a low lcost and at a high rate of output. The material is referably made in the form of asheet o the usual size and its weight isnot substantially different from that of pla-in metal sheets, although it is considerably thicker.

The new material includes a core of a non-metallic substance, and may be in the form of a hardened plastic mass or of a sheet of flexible fibrous material. A bituminousl mastic including an asphaltic compound is suitable or the core may be of a heavy sheet material, such as paper, and* preferably a paper impregna-ted with a water-proofing substance. The plastic type of core 1s preferably produced by a continuous process' and, as rapidly as it is formed, it is encased within a layer oflmetal. This may be done by forming the core by an extrusion and then wrapping the core with a strip of metal laid about the core helically in a pluralit of convolutions so as to form continuous metallic layer.

ter rusting be- 1926. Serial No. 107,041.

Over this metallic layer, which extends from end to end of the core, is wrapped a protective jacket which may take the form of a strip of flexible fibrous material wrapped over the metal layer in a series of convolutions. Over the layer of brous material is applied a sealing jcket, preferablyl in the form of a'waterproo capable of withstanding solar heat. 'If de sired, the sealing layer may be covered with a surfacing nots, of the type of sand, crushed slate, and the like. This surfacing material may best be applied to the surface of the Sealing layer while the latter is ,still tacky, being partially submerged therein by the action of pressure.

For a better understanding of the invention, reference may be had to the accompanying drawing, in which Fig. 1 is a lface view of a strip of the new material, but with the sent,

Fig. -2 is a similar View, with portions of the overlying layers broken away,'

Fig. 3 is a sectional view on the line 3 3 of Fig. 2,

Fig. 4 is a view similar to Fig. 2, but showing the jacketing strips in a different arrangement, and

Fig. 5 is a view similar to a corrugated material.

Referring now to the drawings, the new roon Vmaterial includes a core 10,-which is here sown as relatively flat, although the shape of the core will kind of product which is to be made. This core may be of any suitable, material of an insulating character, and if made of a plastic substance it may be produced by an extrusion operation which is inexpensive and simple. The plastic substance should be one which will harden stance, as a bituminous substance, and if desired, may contain a filler, such as crushed mineral mattelf., Instead of using thamastic, a suitable grade of a fibrous material, such as paper, may 'be employed, and for this purpose it is preferable to use paper which has been rendered waterproof by the use of asphalt.

Enclosing this core is a jacket of metal 1l which may be conveniently applied in the form of a metallic strip, preferably of a li ht gau e steel wound about the core heliwcaly an with the convolutions partiall overlapping, as indicated at 12, so that the plastic substance, such as asphaltJ material, such as .mineral prodsurfacing layer aby Fig. 3, showing be dependent on the on setting, such, for inben core is encased in a substantially continuous metallic layer. This metallic layer provides a reinforcement for the finished product, and gives it the necessary strength and r1- gidity. The overlapping edges' o f the convolutions provide a double thickness of metal, which act as stifening ribs, and which are inclined at opposite angles on the opposite faces of the core, as will readily be apparent from a consideration of the manner in which the metal is applied. By wrapping the metal in this manner, both longitudinal edges of the core are protected against injury. Encasing the metal is the jacket layer 13, weather. I preferto use for this purpose a heavy paper rendered waterproof by impregnation with a substance, such as asphalt. .The strip of fibrous mateiial 1s continuous from end to end of the core, and is wrapped about the core helically as shown, the convolutions partially overlapping as 1ndicated at 14. If desired, and as shown in Fig. 4, the strip of metal 11 may be wound in one direction helically around the core, aid the strip of fibrous material 13 wound with the opposite lay. When the strip of fibrous material is wound as shown in Fig. 2, the convolutions of the outer layer should break joint with the convolutions of the metal.

Applied over the jacketing layer of paper isa sealing layer 15 of a suitable waterproof composition. Asphaltic material is satisfactory for the purpose, and the asphalt used should be one which has a melting point sufficient to withstand solar heat.

Appliedl over the surface of the sealing layer, is a layer 16 of material for wear purposes. This may be any of the usual sub stances, such as sand, crushed slate, and the like, used in this way. This wear surface not only protects the base. against injury, but in addition, it improves the appearance of the material.

In the manufacture of the new material I prefer to employ a process similar to that illustrated and described in my (1o-pending application Ser. No. 101,877, iled April 14, 1926. In this application there is shown a process and apparatus by vwhich a core is continuously formed of a plastic material by an extrusion operation. This material is forced from the extrusion orifices, which are arranged to produce a tube of the plastic compound, around which is wrapped the metallic strip. Over this is laid the strip of the fibrous material, and the tubular core, with these jacketin layers applied, passes from the extrusion evice and 1s led through rolls which collapsethe core, consolidating it into a single layer. The convolutions of the metal strip are similarly flattened and the' `ressure applied is suilicient to give the (is in the metal at the edges of the core which protects the metal from the a permanent set. Passing from the shaping` rolls, the j acketed core is led through a coating device, by which the layer of asphaltic material is applied, after which the granular surface is laid. Preferably, the granular material is applied over the surface of the asphalt while the latter is still tackiy, and is partially embedded therein to be he diby the asphalt when the latter cools and sets.

The material illustrated in Figs. l and 3 is of a flat cross-section and after it is produced by a continuous operation in the form of a flat sheet of indefinite. length, this sheet is cut into lengths suitable for ordinary building purposes. Such sheets are commonly of approximately three feet in width and six to eight feet long. If desired, however, a corrugated product, such as that illustrated in Fig. 5, may be produced, this prod- -uct being made in the same way as the flat material but being passed through corrugating rolls in the course of manufacture. The

corrugations will preferably extend length-- wise of the sheet.

The new material is primarily adapted for industrial building purposes, and may be laid in the usual way on the building structural members. The material is much superior to ordinar sheet iron commonly used heretofore for t is same purpose, because while it includes a metallic jacket which gives the product the desired strength and rigidity, the metal is entirely concealed and protected so that corrosion is prevented. At the same time, the metal is encased and in turn encases insulating material so that heat cannot be transmitted through the new product with rapidity. The use of the sealing "layer protects the two jacket layers and in turn affords a' means for applyingrthe anular wear material which en ances t e appearance of the product. The new material may be considered as a protected metal ,product, although it is superior to the protected metal building elements heretofore manufactured, because the metal is em lo ed in the form of a. strip of relatively ig t wei ht. The metal layer, which is of generally tu ular form, is protected on both faces and also on its interior against rusting. The use of the metal in the form of a helically laid strip having overlapping edges, permits the use of much lighter gauge material without sacrifcing the strength andstiffness of the final product. f

I claim: 1. A prepared material for roofing and other similar purposes which comprises a non-metallic core, a layer of metal encasing the core and a waterproof jacket over the metallic layer.

2.' A prepared material for roofing and other similar purposes, which comprises a relatively flat non-metallic core, a substan# tally continuous layer of metal encasing the of metal Wound about the core in a core, brous material encasing the metallic layer.

3. A prepared material for roofing and other similar purposes, which comprises a non-metallic core, a strip of metal laid about the core in a plurality of convolutions and forming a substantially continuous metallic layer, and a waterproof jacket encasing the metallic layer with the core inside it.

4. A prepared material for rooting and other similar purposes, which comprises a non-metallic core, a strip of metal Wound around the core helically in successive partially overlapping convolutions to form a substantially continuous metallic layer, and a Waterproof jacket encasing the metallic layer with the core inside it.

5. A prepared material for roofing and other similar purposes, which comprises a non-metallic core -of insulatin material, a strip of metal Wound about t e core from one end to the other in overlapping convolutions, and a stri of Waterproof flexible iibrous material laid over the metal to form a substantially continuous jacket.

6. A prepared material for roofing and other similar purposes, which comprises a non-metallic core of plastic material, a strip plurality of convolutions, and a waterproof jacket encasing the metal layer.

7. A prepared material for roofing and other similar purposes, which comprises a relatively lat core of plastic material, a strip of metal Wound helically about the core to form a substantially continuous layer of metal, a strip of llexible fibrous material wound over the metal, and a sealing layer of and a waterproof jacket including li-l layer forming wound over the metal and a sealing layer of waterproof material applied over the librous strip.

9. A prepare-d material for roofing and other similar purposes, which comprises a core of asphaltic material, a strip of thin metal wrapped about the core to form a substantially continuous metallic layer, a strip of fiexible ibrous material wrapped about the core over the metal, and a layer of bituminous material applied over the fibrous layer and forming a waterproof seal.

10. A product for building and other pur- L poses, which comprises a sheet of considerable extent formed of a relatively at core of non-metallic material, a metallic strip Wrapped about the core helically from one end to the other and forming a substantially continuous metallic layer, and a waterproof a protective jacket for the metal and core.

11. A prepared material for roofing and other similar purposes, which comprlses a non-metallic core, a layer of metal encasing the core, a waterproof jacket encasing the metallic layer, and granular wear material covering one surface of the waterproof jacket.

In testimony whereof I aflix m signature.

THOMAS RO INSON. 

